Machinability improving composition

ABSTRACT

An iron-based powder composition is provided comprising, in addition to an iron-based powder, a minor amount of a machinability improving additive comprising at least one silicate from the group of phyllosilicates. The technology further concerns the use of the machinability improving additive and a method for producing an iron-based sintered part having improved machinability.

TECHNICAL FIELD OF THE INVENTION

The invention refers to a powder metal composition for production ofpowder metal parts, as well as a method for producing powder metalparts, having improved machinability.

BACKGROUND OF THE INVENTION

One of the major advantages of powder-metallurgical manufacture ofcomponents is that it becomes possible, by compacting and sintering, toproduce blanks of final or very close to final shape. There are howeverinstances where subsequent machining is required. For example, this maybe necessary because of high tolerance demands or because the finalcomponent has such a shape that it cannot be pressed directly butrequires machining after sintering. More specifically, geometries suchas holes transverse to the compacting direction, undercuts and threads,call for subsequent machining.

By continuously developing new sintered steels of higher strength andthus also higher hardness, machining has become one of the majorproblems in powder-metallurgical manufacture of components. It is oftena limiting factor when assessing whether powder-metallurgicalmanufacture is the most cost-effective method for manufacturing acomponent.

Today, there are a number of known substances which are added toiron-based powder mixtures to facilitate the machining of componentsafter sintering. The most common powder additive is MnS, which ismentioned e.g. in EP 0 183 666, describing how the machinability of asintered steel is improved by the admixture of such powder.

U.S. Pat. No. 4,927,461 describes the addition of 0.01 and 0.5% byweight of hexagonal BN (boron nitride) to iron-based powder mixtures toimprove machinability after sintering.

U.S. Pat. No. 5,631,431 relates to an additive for improving themachinability of iron-based powder compositions. According to thispatent the additive contains calcium fluoride particles which areincluded in an amount of 0.1-0.6% by weight of the powder composition.

The Japanese patent application 08-095649 describes a machinabilityenhancing agent. The agent comprises Al₂O₃—SiO₂—CaO and has an anorthiteor a gehlenite crystal structure. Anortithe is a tectosilicate,belonging to the feldspar group, having Mohs hardness of 6 to 6.5 andgehlenite is a sorosilicate having Mohs hardness of 5-6.

U.S. Pat. No. 7,300,490 describes a powder mixture for producing pressedand sintered parts consisting of a combination of manganese sulfidepowder (MnS) and calcium phosphate powder or hydroxy apatite powder.

WO publication 2005/102567 discloses a combination of hexagonal boronnitride and calcium fluoride powders used as machining enhancing agent.

Boron containing powders such as boron oxide, boric acid or ammoniumborate, in combination with sulphur is described in U.S. Pat. No.5,938,814.

Other combinations of powder to be used as machining additives aredescribed in EP 1985393A1, the combination containing at least oneselected from talc and steatite and a fatty acid.

Talc as machining enhancing agent is mentioned in JP1-255604. Talcbelongs to the group of phyllosilcates, consisting silicon tetrahedrallayers, enclosing a magnesium hydroxide octahedral layer.

The application EP1002883 describes a powdered metal blend mixture formaking metal parts, especially valve seat inserts. The blends describedcontain 0.5-5% of solid lubricants in order to provide low friction andsliding wear as well as improvement in machinability. In one of theembodiments, mica is mentioned as a solid lubricant. These types ofpowder mixtures, used for production of wear resistant and hightemperature stable components, always contain high amounts of alloyingelements, typically above 10% by weight and hard phases, typicallycarbides.

U.S. Pat. No. 4,274,875 teaches a process for the production ofarticles, similar to what is described in EP1002883, by powdermetallurgy including the step of adding powdered mica to the metalpowder before compaction and sintering in amounts between 0.5 to 2weight %. Specifically, it is disclosed that any type of mica can beused.

Further, the Japanese patent application JP10317002, describes a powderor a sintered compact having a reduced friction coefficient. The powderhas a chemical composition of 1-10 weight % of sulphur, 3-25 weight ofmolybdenum and the balance iron. Further a solid lubricant and hardphase materials are added.

Machining of pressed and sintered components is very complex and isinfluenced by parameters such as type of alloying system of thecomponent, sintered density of the component and size and shape of thecomponent. It is also obvious that type of machining operation and speedof machining are parameters which have a great importance of the outcomeof the machining operation. The diversity of proposed machiningenhancing agents to be added to powder metallurgical compositionsreflects the complex nature of the PM machining technology.

SUMMARY OF THE INVENTION

The present invention discloses a new additive for improving themachinability of sintered steels. Especially for low alloyed sinteredsteels having a content of alloying elements below 10% by weight andbeing free from hard phase materials. The new additive is designed forimproving the machinability of such sintered steels subjected to chipremoving operations such as drilling, turning, milling and threading.Further the new additive can be used in components to be machined byseveral types of tool materials such as high speed steel, tungstencarbides, cermets, ceramics and cubic boron nitride and the tool mayalso be coated.

An object of the present invention is thus to provide a new additive fora powder metal composition for improvement of machinability.

Another object of the present invention is to provide such additive tobe used at various machining operations of different types of sinteredsteels.

Another object of the present invention is to provide a newmachinability enhancing substance having no or negligible impact on themechanical properties of the pressed and sintered component.

A further object of the invention is to provide a powder metallurgicalcomposition containing the new machinability enhancing additive, as wellas a method of preparing a compacted part from this composition.

It has now been found that by including a machinability enhancing agentcomprising a defined special type of silicate in a powder composition, asurprisingly great improvement of the machinability of sinteredcomponents having various microstructures and sintered densities isachieved. Furthermore, the positive effect on machinability is obtainedeven at very low added amounts, thus the negative impact on thecompressibility by adding additional substances will be minimized. Ithas also been shown that the influence on the mechanical properties fromthe added silicate is acceptable.

The invention thus provides an iron-based powder composition comprising,in addition to an iron-based powder, a minor amount of a machinabilityimproving additive, said additive comprising at least one silicate fromthe group of phyllosilicates. The invention also provides the use of aphyllosilicate as a machinability improving agent in an iron-basedpowder composition. The invention further provides a method forproducing an iron-based sintered part having improved machinabilitycomprising the steps of: preparing an iron-based powder composition asabove, compacting the iron-based powder composition at a compactionpressure of 400-1200 MPa, sintering the compacted part at a temperatureof 1000-1300° C. and optionally heat treating the sintered part.

According to the present invention, at least one of the above objects,as well as other objects evident from the below discussion, is achievedby the different aspects of the present invention.

According to one aspect of the present invention, there is provided aniron-based powder composition comprising, in addition to an iron-basedpowder, a minor amount of a machinability improving additive in powderform, said additive comprising at least one silicate from the groupconsisting of phyllosilicates.

The phyllosilicate may be chosen e.g. among clay minerals, such asbentonite, kaolinite and smectite, among chlorites, or among micas suchas phlogopite, muscovite, biotite and margarite.

According to another aspect of the present invention, there is provideda use of a phyllosilicate comprised in a machinability improvingadditive in an iron-based powder composition.

According to another aspect of the present invention, there is provideda method of preparing an iron-based powder composition, comprising:providing an iron-based powder; and admixing the iron-based powder witha machinability improving additive in powder form, the machinabilityimproving additive comprising at least one phyllosilicate.

According to another aspect of the present invention, there is provideda method for producing an iron-based sintered part having improvedmachinability, comprising: preparing an iron-based powder compositionaccording to the above aspect; compacting the iron-based powdercomposition at a compaction pressure of 400-1200 MPa; sintering thecompacted part at a temperature of 1000-1300° C.; and optionally heattreating the sintered part.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 displays a schematic drawing of how the wear of the insertcutting edge is measured, i.e. the distance between the two arrows inthe figure, for the machinability index for examples 1, 3, 4, 5, 7, and8.

FIG. 2 is a schematic diagram illustrating the effect of averageparticle size of the machinability improving agents muscovite andphlogopite, respectively, on a relative machinability improving index.

DETAILED DESCRIPTION OF THE INVENTION

The machinability enhancing agent comprises a defined silicate,classified as phyllosilicates, which may be characterised by having aMohs hardness below 5, preferable below 4. The phyllosilicate has aflake crystal structure containing layers of silicon tetrahedralscombined with layers of octahedral structures of hydroxides. Preferablysome of the silicon atoms in the tetrahedrals may be replaced by otheratoms such as aluminum atoms, the silicate thus being denotedaluminate-silicate. Alternatively, the aluminum atoms are present in theoctahedral structures, or the aluminum atoms will be present in bothstructures.

Examples of silicates that may be included in the new machinabilityenhancing additive are:

micas such as:

phlogopite KMg₃(OH,F)₂[AlSi₃O₁₀],

muscovite KAl₂(OH)₂[AlSi₃O₁₀],

biotite K(Mg,Fe)₃(OH)₂[AlSi₃O₁₀], and

margarite CaAl₂(OH)₂[Al₂Si₂O₁₀];

silicates belonging to the chlorite group;

clay minerals such as:

kaolinite Al₂(OH)₄[Si₂O₅];

clay minerals belonging to the smectite group such as:

aliettite Ca_(0.2)Mg₆(Si,Al)₈O₂₀(OH)₄*4H2O,

beidellite (Na,Ca_(0.5))_(0.3)Al₂(Si,Al)₄O₁₀(OH)₂*nH₂O,

hectorite Na_(0.3)(Mg,Li)₃Si₄O₁₀(OH,F)₂,

montmorillonite (Na,Ca)_(0.33)(Al,Mg)₂Si₄O₁₀(OH)₂*nH₂O,

nontronite Na_(0.3)Fe₂(Si,Al)₄O₁₀(OH)₂*nH₂O,

saponite Ca_(0.25)(Mg,Fe)₃(Si,Al)₄O₁₀(OH)₂*nH₂O,

stevensite (Ca,Na)_(x)Mg₃Si₄O₁₀(OH)₂,

volkonskoite Ca_(0.3)(Cr,Mg,Fe)₂(Si,Al)₄O₁₀(OH)₂*4H₂O, and

yakhontovite (Ca,Na)_(0.5)(Cu,Mg,Fe)₂Si₄O₁₀(OH)₂*3H₂O.

Normally, silicate minerals occur in nature as a combination of definedminerals, commercially it exists therefore different combinations ofchemically defined silicates or intermediates thereof, such as varioustypes of bentonites, containing montmorillonite. The present inventionis not restricted to silicates defined by a single specific structurebut also includes combinations and intermediates of the silicatesdescribed above.

The reason why the silicates used according to the present invention mayhave hardness below 5, preferably below 4, according to Mohs scale, andmay have a layered structure, is that it has now been found that suchsilicates will contribute to machining properties even at relative lowtemperatures during machining of the sintered body, compared to hardersilicates. Negative impact on the tool, caused by during machiningevolved heat, can thus be avoided. Silicates having a higher hardnessmay not contribute to the lubrication during compaction and ejection ofthe compacted body from the dye. Low hardness in combination with alayered crystal structure of the silicates added is then favourable andenhances the lubricating properties, thus allowing lower added amount ofconventional lubricants, enabling higher green densities to be reached.

Furthermore, without being bound to any specific theory it is believedthat the presence of aluminum atoms in the silicate may have a positiveeffect on the machining properties and contributes to the goodmachinability properties regardless of the metallograhic structures ofthe components to be machined.

The new additive may include or be mixed with other known machiningenhancing additives such as manganese sulfide, hexagonal boron nitride,other boron containing substances and/or calcium fluoride.

The amount of additive in the iron-based powder composition may bebetween 0.05% and 1.0 by weight, preferably between 0.05% and 0.5%,preferably between 0.05% and 0.4%, preferably between 0.05% and 0.3% andmore preferably between 0.1 and 0.3% by weight. Lower amounts may notgive the intended effect on machinability and higher amounts may have anegative influence on mechanical properties. Thus, the amount ofmachinability improving agent added to the iron-based powder compositionmay be less than 0.5 wt %, conveniently 0.49 wt % or less, preferably0.45 wt % or less, more preferably 0.4 wt % or less, such as 0.3 wt % orless, or 0.2 wt % or less, or 0.15 wt % or less.

The particle size, X₉₉, of the new additive according to the inventionmay be below 50 μm, preferably below 30 μm, more preferably below 20 μm,such as 15 μm or less. The corresponding mean particle size, X₅₀, may bebelow 20 μm, preferably below 15 μm, more preferably 10 μm or less, suchas 5 μm or less. The particle size, X₉₉, may essentially be at least 1μm. If the particle size is below 1 μm it may be difficult to obtain ahomogeneous powder mixture. A particle size above 50 μm may negativelyinfluence the machinability and mechanical properties.

The machinability improving effect of the machinability improvingadditive of the present invention may be especially pronounced when thecomponent to be machined has a martensitic structure, or a heterogeneousstructure comprising a martensitic structure.

Iron Based Powder Composition

Powder Types

This new machinability improvement powder can be used in essentially anyferrous powder compositions. Thus the iron-based powder may be a pureiron powder such as atomized iron powder, reduced powder, and the like.Also pre-alloyed powders including alloying elements such as Ni, Mo, Cr,V, Co, Mn, Cu, may be used as well as partially alloyed steel powder. Ofcourse, these powders may be used in a mixture.

The machinability improving additive is present in the composition inpowder form. The additive powder particles may e.g. be mixed with theiron-based powder as free powder particles or be bound to the iron-basedpowder particles e.g. by means of a binding agent.

Other Additives

The powder composition according to the invention may also include otheradditives such as graphite, binders and lubricants and otherconventional machinability improving agents. Lubricant may be added at0.05-2% by weight, preferably 0.1-1% by weight. Graphite may be added at0.05-2% by weight, preferably 0.1-1% by weight.

Process

The powder-metallurgical manufacture of components according to theinvention may be performed in a conventional manner, i.e. by thefollowing process: iron-based powder, e.g. the iron or steel powder, maybe admixed with any desired alloying elements, such as nickel, copper,molybdenum and optionally carbon as well as the machinability improvingadditive according to the invention in powder form. The alloyingelements may also be added as prealloyed or diffusion alloyed to theiron based powder or as a combination between admixed alloying elements,diffusion alloyed powder or prealloyed powder. This powder mixture maybe admixed with a conventional lubricant, for instance zinc stearate oramide wax, prior to compacting. Finer particles in the mix may be bondedto the iron based powder by means of a binding substance. The powdermixture may thereafter be compacted in a press tool yielding what isknown as a green body of close to final geometry. Compacting generallytakes place at a pressure of 400-1200 MPa. After compacting, the compactmay be sintered at a temperature of 1000-1300° C. and is given its finalstrength, hardness, elongation etc. Optionally, the sintered part may befurther heat-treated.

EXAMPLES

The present invention will be illustrated in the following non-limitingexamples:

Machinability Enhancing Agents

The following substances were used as examples of machinabilityenhancing agents according to the invention:

A muscovite containing powder, having a particle size, X₉₉, essentiallybelow 20 μm and a chemical composition expressed as weight % oxidesaccording to below;

SiO₂ 48.0 Al₂O₃ 33.3 K₂O 10.1 FeO 2.8 MgO 0.3 Loss on ignition 5.5

A phlogopite containing powder, having a men particle size, X₅₀, about18 μm and the particle size, X₉₉, essentially below 45 μm and a chemicalcomposition expressed as weight % oxides according to below;

SiO₂ 39.5 Al₂O₃ 10.3 K₂O 12.8 FeO 10.3 MgO 22.7 CaO 0.5 Loss on ignition3.0

A powder containing minerals belonging to the smectite group, having aparticle size, X₉₉, essentially below 20 μm and a chemical compositionexpressed as weight % oxides according to below;

SiO₂ 68.2 Al₂O₃ 10.9 K₂O 0.3 FeO 1.3 MgO 17.0 CaO 1.1 Na₂O 1.2

Loss on ignition (Loss on ignition not measured, chemical analysiscalculated when l.o.i excluded)

A calcium bentonite containing powder having a particle size, X₉₉,essentially below 15 μm and a chemical composition expressed as weight %oxides according to below;

SiO₂ 55.1 Al₂O₃ 23.3 K₂O 2.9 FeO 1.6 MgO 2.9 CaO 4.7 Na₂O 1.9 Loss onignition 9.5

Example 1 Machinability Investigation, Carried Out with a TurningOperation, on As-Sintered PM Material

The bentonite powder was mixed with a metal powder, a water atomizediron powder AHC100.29 available from Höganäs AB, Sweden. The metalpowder was also mixed with 2 wt % copper powder, 0.8% of ethylenebisstearamide as lubricant, and graphite, 0.8 wt %.

The metal powder mixes according to table 1 were compacted tostandardised TRS bars according to ISO 3325 and rings with an outerdiameter of 55 mm, an inner diameter of 35 mm and a height of 20 mm, toa green density of 6.9 g/cm³.

The TRS bars and rings were sintered in a laboratory mesh belt furnaceat 1120° C. for 20 minutes in a mix of 10% hydrogen and 90% nitrogen.The obtained micro structure of the samples was pearlitic. The sinteredTRS bars were used to determine transversal rupture strength accordingto ISO 3325 and the sintered rings were used in turning tests todetermine a machinability index as can be seen in Table 2.

The machinability index is defined as the flank wear on a turning tool,i.e. the removed material from an insert cutting edge. FIG. 1 discloseshow this wear is measured. Turning was performed on the outer diameterof the rings with a tungsten carbide insert, with constant spindle speedand constant feed without coolant.

Table 1 shows that the mechanical properties of the compacted rings arealmost unaffected by the added bentonite. However, for rings with addedbentonite a remarkable improvement in machinability is a fact, which isshown in Table 2. The machinability index for rings comprising bentonitewas reduced by almost 50% (i.e. the wear of the insert cutting edge wasreduced) compared to rings without this additive, for the same cuttingdistance.

TABLE 1 BENTONITE TRS MIX [%] DC [%] HRB [MPa] 1 — 0.21 77-80 945 2 0.20.18 77-78 952 DC is the dimensional change in length for thetransversal rupture strength bar during sintering HRB is the Rockwell Bhardness for the transversal rupture strength bar TRS is the transversalrupture strength for the transversal rupture strength bar

TABLE 2 BENTONITE SPINDLE CUTTING M. INDEX MIX [%] SPEED [rpm] DISTANCE[m] [μm] 1 — 1800 168 850 2 0.2 1800 168 450 2 0.2 1800 333 850 Spindlespeed is the rotation per minutes in the turning lathe. Cutting distanceis the length made by the insert in engagement in sintered ring. M.index (Machinability index) is the flank wear in μm on the insertcutting edge after covered cutting distance (see FIG. 1).

Example 2 Machinability Investigation, Carried Out with DrillingOperation, on As-Sintered PM Material

The muscovite and the phlogopite powder were mixed with a metal powderDistaloy AE, available from Höganäs AB, Sweden, which is pure irondiffusion alloyed with 0.5% of Mo, 4% of Ni and 1.5% of Cu. The metalpowder was also mixed with a lubricant, 0.8 wt % EBS(etylenbisstearamide) and 0.5 wt % graphite.

The material mixes in Table 3 were compacted to standardised tensiletest bars according to ISO 2740 and to discs with a diameter of 80 mmand a height of 12 mm, to a green density of 7.10 g/cm³. The tensilebars and discs were sintered in a laboratory mesh belt furnace at 1120°C. for 30 minutes in a mix of 10% hydrogen and 90% nitrogen. Theobtained micro structure of the samples was heterogeneous, containingferrite, nickel rich austenite, pearlite, bainite and martensite.

The discs were used in drill tests to determine a machinability index ascan be seen in Table 4. This index is defined as the number of holes perdrill that can be machined before the drill is totally worn out, i.e. atotal drill break down. Drilling was performed with high speed steelsdrill, diameter 03.5, with constant speed and constant feed without anycoolant.

Table 3 shows that when the mica powders muscovite and phlogopite areadded only minor deviations in mechanical properties are found.Machinability is remarkable improved with Phlogopite and even moreextraordinarily improved with muscovite (i.e. considerably more holescould be drilled) as shown in Table 4.

TABLE 3 MUSCO- PHLOG- VITE OPITE DC YS TS A MIX [%] [%] [%] HV10 [MPa][MPa] [%] 1 — — −0.15 211 373 737 2.5 2 0.3 — −0.13 203 362 693 2.2 3 —0.3 −0.09 205 371 718 2.4 DC is the dimensional change in length for thetensile strength bar during sintering HV10 is the Vickers hardness forthe tensile strength bar YS is the yield strength for the tensilestrength bar TS is the tensile strength for the tensile strength bar Ais the plastic elongation during tensile strength test

TABLE 4 MUSCOVITE PHLOGOPITE SPINDLE M. [DRILLED MIX [%] [%] SPEED [rpm]HOLES] 1 — 3820 78 2 0.3 — 3820 415 3 — 0.3 3820 136 Spindle speed isthe rotation per minutes in the drilling machine M. index (Machinabilityindex) is the average number of drilled holes before total drill breakdown of the drill.

Example 3 Machinability Investigation, Carried Out with a TurningOperation, on Sintered, Quenched and Tempered PM Material

The bentonite powder was mixed in with a metal powder, a water atomizediron powder AHC100.29 available from Höganäs AB, Sweden. The metalpowder was also mixed with 2 wt % copper powder, a lubricant, 0.8 wt %EBS (etylenbisstearamide), and graphite, 0.8 wt %.

The material mixes according to table 5 were compacted to rings with anouter diameter of 55 mm, an inner diameter of 35 mm and a height of 20mm, to a green density of 6.9 g/cm³. The rings were sintered in alaboratory mesh belt furnace at 1120° C. for 20 minutes in a mix of 10%hydrogen and 90% nitrogen. After sintering the rings were heat treatedat 980° C. for 30 minutes then quenched in oil. Directly after oilquenching the rings was tempered at 200° C. in one hour in air. Theobtained micro structure was fully martensitic.

The rings were used in turning tests to determine a machinability indexas can be seen in Table 6. The machinability index is defined as theflank wear on a turning tool, i.e. the removed material from an insertcutting edge. FIG. 1 discloses how this wear is measured. Turning wasperformed on the outer diameter of the ring with silicon nitride ceramicinserts, with constant spindle speed and constant feed without coolant.

Table 5 shows that the hardness of heat treated rings is unaffected bythe added bentonite. However, the machinability is remarkably improvedwhen bentonite is used as shown in Table 6. The machinability index forrings comprising bentonite was reduced by more than 50% (i.e. the wearof the insert cutting edge was reduced) compared to rings without thisadditive, for the same cutting distance.

TABLE 5 BENTONITE MIX [%] HRC 1 — 32-34 2 0.2 32-34 HRC is the RockwellC hardness for the heat treated ring

TABLE 6 BENTONITE SPINDLE CUTTING M. INDEX MIX [%] SPEED [rpm] DISTANCE[m] [μm] 1 — 1800 168 160 2 0.2 1800 168 90 2 0.2 1800 809 160 Spindlespeed is the rotation per minutes in turning lathe Cutting distance isthe length made by the insert in engagement in sintered ring. M. index(Machinability index) is the flank wear on the insert cutting edge aftercovered cutting distance.

Example 4 Machinability Investigation, Carried Out with a TurningOperation, on Sinter Hardened PM Material

The bentonite powder was mixed in with a metal powder, a water atomizedsteel powder Astaloy A, available from Höganäs AB, Sweden, which ispre-alloyed with 1.9% Ni and 0.55% Mo. The metal powder was also mixedwith 2 wt % copper powder, a lubricant, 0.8 wt % EBS(etylenbisstearamide), and graphite, 0.8 wt %.

The material mixes according to table 7 were compacted to rings with anouter diameter of 55 mm, an inner diameter of 35 mm and a height of 20mm, to a green density of 6.9 g/cm³. The rings were sinter hardened in aproduction furnace at 1120° C. for 20 minutes in a mix of 10% hydrogenand 90% nitrogen with 2.2° C./s cooling rate. After sinter hardening therings were tempered at 200° C. for 30 minutes in air. The obtained microstructure was fully martensitic.

The rings were used in turning tests to determine a machinability indexas can be seen in Table 8. The machinability index is defined as theface wear on a turning tool, i.e. the removed material from an insertcutting edge. FIG. 1 discloses how this wear is measured. Turning wasperformed on the outer diameter of the ring with silicon nitride ceramicinserts, with constant spindle speed and constant feed without coolant.

Table 7 shows that hardness of heat treated rings is slightly harder bythe added amount of the bentonite. The machinability is remarkableimproved when bentonite is used as shown in Table 8. The machinabilityindex for rings comprising bentonite was reduced by about 60% (i.e. thewear of the insert cutting edge was reduced) compared to rings withoutthis additive, for the same cutting distance.

TABLE 7 BENTONITE MIX [%] HRC 1 — 33-34 2 0.2 35-38 HRC is the RockwellC hardness for the heat treated ring

TABLE 8 BENTONITE SPINDLE CUTTING M. INDEX MIX [%] SPEED [rpm] DISTANCE[m] [μm] 1 — 1800 168 296 2 0.2 1800 168 100 2 0.2 1800 809 143 Spindlespeed is the rotation per minutes in the turning lathe Cutting distanceis the length made by the insert in engagement in sintered ring. M.index (Machinability index) is the flank wear on the insert cutting edgeafter covered cutting distance.

Example 5 Machinability Investigation, Carried Out with a TurningOperation, on Sinter Hardened PM Material

The bentonite powder was mixed in with a metal powder, a water atomizedsteel powder Astaloy CrL, available from Höganäs AB, Sweden, aprealloyed powder having 1.5% Cr and 0.2% Mo. The metal powder was alsomixed with 2 wt % copper powder, a lubricant, 0.8 wt % EBS(etylenbisstearamide), and graphite, 0.75 wt %.

The mixes according to table 9 were compacted to rings with an outerdiameter of 55 mm, an inner diameter of 35 mm and a height of 20 mm, toa green density of 6.9 g/cm³. The rings were sinter hardened in aproduction furnace at 1120° C. for 20 minutes in a mix of 10% hydrogenand 90% nitrogen with 2.2° C./s cooling rate. After sinter hardening therings were tempered at 200° C. for 30 minutes in air. The obtained microstructure was fully martensitic.

The rings were used in turning tests to determine a machinability indexas can be seen in Table 10. The machinability index is defined as theface wear on a turning tool, i.e. the removed material from an insertcutting edge. FIG. 1 discloses how this wear is measured. Turning wasperformed on the outer diameter of the rings with silicon nitrideceramic inserts, with constant spindle speed and constant feed withoutcoolant.

Table 9 shows that hardness of heat treated rings is slightly harder bythe added amount of the bentonite. Machinability is remarkable improvedwhen Bentonite is used as shown in Table 10. The machinability index forrings comprising bentonite was reduced by about 75% (i.e. the wear ofthe insert cutting edge was reduced) compared to rings without thisadditive, for the same cutting distance.

TABLE 9 BENTONITE MIX [%] HRC 1 — 33-35 2 0.2 33-36 HRC is the RockwellC hardness for the heat treated ring

TABLE 10 BENTONITE SPINDLE CUTTING M. INDEX MIX [%] SPEED [rpm] DISTANCE[m] [μm] 1 — 1800 168 210 2 0.2 1800 168 56 2 0.2 1800 809 79 Spindlespeed is the rotation per minutes in the turning lathe Cutting distanceis the length made by the insert in engagement in sintered ring. M.index (Machinability index) is the flank wear on the insert cutting edgeafter covered cutting distance.

Example 6 Machinability Investigation, Carried Out with DrillingOperation, on Sinter Hardened PM Material

The muscovite, the phlogopite and the smectite powder were mixed with ametal powder, a water atomized steel powder Astaloy CrM, available fromHöganäs AB, Sweden, which is iron pre alloyed with 3% Cr and 0.5 Mo. Themetal powder was also mixed with a lubricant, 0.8 wt % EBS(etylenbisstearamide) and 0.55 wt % graphite.

The material mixes in Table 11 were compacted to standardised tensiletest bars according to ISO 2740 and to discs with a diameter of 80 mmand a height of 12 mm, to a green density of 7.10 g/cm³. The tensilebars and discs were sinter hardened in a laboratory mesh belt furnace at1120° C. for 30 minutes in a mix of 10% hydrogen and 90% nitrogen with2.2° C./s cooling rate. After sinter hardening the TS bars and discswere tempered at 200° C. for 30 minutes in air. The obtained microstructure was fully martensitic.

The discs were used in drill tests to determine a machinability index ascan be seen in Table 12. This index is defined as a critical cuttingspeed. If a drill could produce the total amount of holes (216) on onedisc at a certain cutting speed without total drill break down, a newdrill together with an increased cutting speed should be carried out atthe following test. Drilling was performed with solid carbide drill,diameter Ø3.5, with constant feed without any coolant.

Table 11 shows that when the muscovite, the phlogopite or smectitepowders are added some minor deviations in mechanical properties arefound. Machinability is remarkable improved with the muscovite, thephlogopite or the smectite allowing increased spindle speed withoutdrill failure as shown in Table 12.

TABLE 11 MUSCO- PHLOG- SMEC- MHV0.05 VITE OPITE TITE (MAR- TS MIX [%][%] [%] HV10 TENSITE) [MPA] 1 — — — 455 698 1055 2 0.3 — — 389 637 908 3— 0.3 — 378 714 837 4 — — 0.3 432 715 992 HV10 is the Vickers hardnessfor the tensile strength bar MHV0.05 is the Micro Vickers martensitehardness for the tensile strength bar TS is the tensile strength for thetensile strength bar

TABLE 12 SPINDLE M. INDEX MUSCO- PHLOGO- SMEC- SPEED [DRILLED MIX VITE[%] PITE [%] TITE [%] [rpm] HOLES] 1 — — — 3638 30 2 0.3 — — 3638 216 20.3 — — 4547 216 3 — 0.3 — 3638 216 3 — 0.3 — 4547 216 4 — — 0.3 3638216 4 — — 0.3 4547 216 Spindle speed is the rotation per minutes in thedrilling machine The testing was interrupted after 216 drilled holes, nofailure of the drills were noticed.

Example 7 Machinability Investigation, Carried Out with TurningOperation, on Sinter Hardened PM Material

The muscovite, the phlogopite and the smectite powder were mixed with ametal powder, a water atomized steel powder Astaloy CrM as in example 6.The metal powder was also mixed with a lubricant, 0.8 wt % EBS(etylenbisstearamide) and 0.55 wt % graphite.

The mixes in table 13 were compacted to standardised tensile test barsaccording to ISO 2740 and to rings with an outer diameter of 64 mm, aninner diameter of 35 mm and a height of 25 mm, to a green density of7.10 g/cm³. The tensile bars and rings were sinter hardened in alaboratory mesh belt furnace at 1120° C. for 30 minutes in a mix of 10%hydrogen and 90 nitrogen with 2.2° C./s cooling rate. The obtainedmicrostructure was fully martensitic.

After sinter hardening the TS bars and rings were tempered at 200° C.for 30 minutes in air. The rings were used in turning tests to determinea machinability index as can be seen in Table 14. The machinabilityindex is defined as the flank wear on a turning tool, i.e. the removedmaterial from an insert cutting edge. FIG. 1 discloses how this wear ismeasured. Turning was performed on the end face of the rings with cubicboron nitride inserts, at constant cutting speed and constant feedwithout coolant.

Table 13 shows that when the powders muscovite, phlogopite or smectiteare added some minor deviations in mechanical properties are found.

Machinability is remarkable improved with muscovite, phlogopite orsmectite are used as shown in Table 14. The machinability index forrings comprising the different additives were considerably reduced (i.e.the wear of the insert cutting edge was reduced) compared to ringswithout these additives, for the same cutting distance.

TABLE 13 MUSCO- PHLOG- SMEC- MHV0.05 VITE OPITE TITE (MAR- TS MIX [%][%] [%] HV10 TENSITE) [MPa] 1 — — — 455 698 1055 2 0.3 — — 389 637 908 3— 0.3 — 378 714 837 4 — — 0.3 432 715 992 HV10 is the Vickers hardnessfor the tensile strength bar MHV0.05 is the Micro Vickers martensitehardness for the tensile strength bar TS is the tensile strength for thetensile strength bar

TABLE 14 CUTTING MUSCO- PHLOG- SMEC- CUTTING DIS- M. VITE OPITE TITESPEED TANCE INDEX MIX [%] [%] [%] [m/min] [m] [μm] 1 — — — 150 1015 2002 0.3 — — 150 1015 60 2 0.3 — — 150 9132 100 3 — 0.3 — 150 1015 80 3 —0.3 — 150 9132 110 4 — — 0.3 150 1015 80 4 — — 0.3 150 9132 80 Cuttingspeed is the ring speed from outer to inner ring diameter expressed inmeter per minutes in turning machine Cutting distance is the length madeby the insert in engagement in sintered ring. M. index (Machinabilityindex) is the flank wear on the insert cutting edge after coveredcutting distance.

Example 8 Machinability Investigation, Carried Out with a TurningOperation, on Sinter Hardened PM Material

The bentonite powder was mixed in with a metal powder, a water atomizedsteel powder Astaloy CrM as in example 6. The metal powder was alsomixed with a lubricant, 0.8 wt % EBS (etylenbisstearamide), andgraphite, 0.6 wt %.

The mixes according to table 15 were compacted to rings with an outerdiameter of 55 mm, an inner diameter of 35 mm and a height of 20 mm, toa green density of 6.9 g/cm³. The rings were sinter hardened in aproduction furnace at 1120° C. for 20 minutes in a mix of 10% hydrogenand 90% nitrogen with 2.2° C./s cooling rate. After sinter hardening therings were tempered at 200° C. for 30 minutes in air. The obtained microstructure was fully martensitic.

The rings were used in turning tests to determine a machinability indexas can be seen in Table 16. The machinability index is defined as theflank wear on a turning tool, i.e. the removed material from an insertcutting edge. FIG. 1 discloses how this wear is measured. Turning wasperformed on the outer diameter of the ring with silicon nitride ceramicinserts, with constant spindle speed and constant feed without coolant.

Table 15 shows that the hardness of heat treated rings is slightlyharder by the added amount of the bentonite. Machinability is remarkableimproved when the bentonite is used as shown in Table 16. Themachinability index for rings comprising bentonite was reduced by about70% (i.e. the wear of the insert cutting edge was reduced) compared torings without this additive, for the same cutting distance.

TABLE 15 BENTONITE MIX [%] HRC 1 — 33-35 2 0.2 33-36 HRC is the RockwellC hardness for the heat treated ring

TABLE 16 BENTONITE SPINDLE CUTTING M. INDEX MIX [%] SPEED [rpm] DISTANCE[m] [μm] 1 — 1800 168 246 2 0.2 1800 168 77 2 0.2 1800 809 177 Spindlespeed is the rotation per minutes in turning lathe Cutting distance isthe length made by the insert in engagement in sintered ring. M. index(Machinability index) is the flank wear on the insert cutting edge aftercovered cutting distance.

Example 9 Machinability Investigation, Carried Out with DrillingOperation, on As-Sintered PM Material

Muscovite and phlogopite powders having different particle sizedistribution, seen in Table 17, were measured with laser diffractionequipment (Sympatec GmbH) according to method Fraunhofer App.ISO13320-1:1999.

TABLE 17 MATERIAL ABBR. X50 X99 MUSCOVITE M1 31.7 128.4 MUSCOVITE M2 8.439.7 MUSCOVITE M3 3.4 12.3 PHLOGOPITE P1 7.4 34.6 PHLOGOPITE P2 4.6 13.6The X50 value is the particle size [μm] where 50 weight % of thepopulation have a particle size below the value. The X99 value is theparticle size [μm] where 99 weight % of the population have a particlesize below the value.

Muscovite and phlogopite powder were mixed with a metal powder DistaloyAE, available from Höganäs AB, Sweden, which is pure iron diffusionalloyed with 0.5% of Mo, 4% of Ni and 1.5% of Cu. The metal powder wasalso mixed with a lubricant, 0.8 wt % EBS (etylenbisstearamide) and 0.5wt % graphite.

The material mixes in Table 18 (expressed as percent by weight) werecompacted to standardized tensile test bars according to ISO 2740 and todiscs with a diameter of 80 mm and a height of 12 mm, to a green densityof 7.10 g/cm³. The tensile bars and discs were sintered in a laboratorymesh belt furnace at 1120° C. for 30 minutes in a mix of 10% hydrogenand 90 nitrogen. The obtained micro structure of the samples washeterogeneous, containing ferrite, nickel rich austenite, pearlite,bainite and martensite.

TABLE 18 MIX M1 [%] M2 [%] M3 [%] P1 [%] P2 [%] 1 — — — — — 2 0.3 — — —— 3 — 0.3 — — — 4 — — 0.15 — — 5 — — 0.30 — — 6 — — — 0.30 — 7 — — — —0.30 M1 = Muscovite powder with particle size distribution X50 = 31.7 μmand X99 = 128.4 μm M2 = Muscovite powder with particle size distributionX50 = 8.4 μm and X99 = 39.7 μm M3 = Muscovite powder with particle sizedistribution X50 = 3.4 μm and X99 = 12.3 μm P1 = Phlogopite powder withparticle size distribution X50 = 7.4 μm and X99 = 34.6 μm P2 =Phlogopite powder with particle size distribution X50 = 4.6 μm and X99 =13.6 μm

The discs were used in drill tests to determine a machinability index ascan be seen in Table 19. This index is defined as the number of holesper drill that can be machined before the drill is totally worn out,i.e. a total drill break down. Drilling was performed with high speedsteels drill, diameter Ø3.5, with constant speed and constant feedwithout any coolant.

Machinability is improved with phlogopite and is even more improved withmuscovite (i.e. considerably more holes could be drilled) as shown inTable 19, except for the coarser muscovite (M1).

TABLE 19 RRELATIVE ADDITIVE ADDITIVE SPINDLE MACHINABILITY MIX [TYPE][WT %] SPEED [rpm] INDEX 1 — — 3820 1 2 M1 0.30 3820 1 3 M2 0.30 38205.3 4 M3 0.15 3820 5.9 5 M3 0.30 3820 11.1 6 P1 0.30 3820 1.9 7 P2 0.303820 2.6 Spindle speed is the rotation per minutes in the drillingmachine Relative machinability index is the ratio of the average numberof drilled holes before total drill break down for each mixture 1-7 andthe average number of drilled holes for mixture 1 (i.e. the mixturewithout the machinability improving additive).

By defining a relative machinability index as the ratio of the averagenumber of drilled holes before total drill break down of the drill andthe average number of drilled holes in material without additive beforetotal drill break down of the drill, a correlation between machinabilityand the particle size distribution (X₅₀) of muscovite becomes evident,as can be seen in FIG. 2.

With decreasing particle size (X₅₀) the influence on machinability issignificant with muscovite with high increasing machinability effect,while with phlogopite a less increasing effect can be found.

As is evident from FIG. 2, the mean particle size X₅₀, is conveniently20 μm or less, preferably 15 μm or less, more preferably 10 μm or less,especially 5 μm or less.

The amount of added machinability agent, as shown for example formuscovite, has an influence on dimensional change, mechanical propertiesand hardness, as can be seen in Table 20.

TABLE 20 MUSCOVITE DC YS TS A MIX [WT %] [%] HV10 [MPa] [MPa] [%] 1 —−0.15 211 373 737 2.5 4 0.15 −0.13 209 372 708 2.2 5 0.30 −0.12 188 356650 2.4 DC is the dimensional change in length for the tensile strengthbar during sintering HV10 is the Vickers hardness for the tensilestrength bar YS is the yield strength for the tensile strength bar TS isthe tensile strength for the tensile strength bar A is the plasticelongation during tensile strength test

The invention claimed is:
 1. An iron-based powder compositioncomprising, in addition to an iron-based powder, a minor amount of amachinability improving additive in powder form, said additivecomprising a bentonite in powder form, wherein the content of themachinability improving additive is 0.05-1% by weight of the iron-basedpowder composition, wherein the iron-based powder comprises less than10% by weight of alloying elements.
 2. The iron-based powder compositionaccording to claim 1, wherein the particle size, X₉₉, of themachinability improving additive is below 50 μm.
 3. The iron-basedpowder composition according to claim 1, wherein the average particlesize, X₅₀, of the machinability improving additive is below 20 μm. 4.The iron-based powder composition according to claim 1, wherein thecontent of the machinability improving additive is 0.05-0.3% by weightof the iron-based powder composition.
 5. The iron-based powdercomposition according to claim 1, wherein the content of themachinability improving additive is 0.05-0.2% by weight of theiron-based powder composition.
 6. The iron-based powder compositionaccording to claim 1, wherein the particle size, X₉₉, of themachinability improving additive is below 30 μm.
 7. The iron-basedpowder composition according to claim 1, wherein the average particlesize, X₅₀, of the machinability improving additive is below 10 μm. 8.The iron-based powder composition according to claim 1, wherein theaverage particle size, X₅₀, of the machinability improving additive isbelow 5 μm.
 9. An iron-based powder composition comprising, in additionto an iron-based powder, a machinability improving additive in powderform, said additive being muscovite, wherein the content of themuscovite is 0.05-0.3 wt %.
 10. The iron-based powder compositionaccording to claim 9, wherein the content of the machinability improvingadditive is 0.2 wt % or less.
 11. The iron-based powder compositionaccording to claim 9, wherein the particle size, X₉₉, of themachinability improving additive is below 50 μm.
 12. The iron-basedpowder composition according to claim 9, wherein the particle size, X₉₉,of the machinability improving additive is below 30 μm.
 13. Theiron-based powder composition according to claim 9, wherein the averageparticle size, X₅₀, of the machinability improving additive is below 20μm.
 14. The iron-based powder composition according to claim 9, whereinthe average particle size, X₅₀, of the machinability improving additiveis below 10 μm.
 15. The iron-based powder composition according to claim9, wherein the average particle size, X₅₀, of the machinabilityimproving additive is below 5 μm.
 16. An iron-based powder compositionaccording to claim 9, wherein the iron-based powder comprises less than10% by weight of alloying elements.
 17. The method for preparing aniron-based powder composition, comprising: providing an iron-basedpowder; and admixing the iron-based powder with a machinabilityimproving additive in powder form, the machinability improving additivecomprising muscovite, wherein the content of the muscovite is 0.05-0.3wt %.
 18. The method for producing an iron-based sintered part havingimproved machinability, comprising: preparing an iron-based powdercomposition according to claim 9; compacting the iron-based powdercomposition at a compaction pressure of 400-1200 MPa; sintering thecompacted part at a temperature of 1000-1300° C.; and optionally heattreating the sintered part.
 19. The method for producing an iron-basedsintered part having improved machinability, comprising: preparing aniron-based powder composition comprising, in addition to an iron-basedpowder, a minor amount of a machinability improving additive in powderform, said additive comprising a bentonite in powder form; compactingthe iron-based powder composition at a compaction pressure of 400-1200MPa; sintering the compacted part at a temperature of 1000-1300° C.; andoptionally heat treating the sintered part.